Non-cohesive Heat Transfer Sheets via Laser Segmentation
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Solution Overview
Problem
Existing heat transfer methods for decorating fabrics result in continuous films that lack flexibility and breathability, leading to durability issues and potential cracking, especially on athletic materials.
Innovation Solution
A method involving a defocused laser to ablate a heat transfer sheet into discrete pieces with gaps between them, creating a decoration with a discontinuous periphery, which includes adhesive and film layers for improved flexibility and breathability, and can be applied to athletic materials using heat and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous films or layers are formed on fabric through heat transfer, then the design or decoration is reliably applied and adheres well to the fabric, but the resulting structure has little flexibility and breathability, which decreases effectiveness of sweat wicking materials and may result in cracking of the design
Solution Approach 1:
The continuous film or layer is segmented into discrete, non-cohesive pieces or regions. This segmentation creates gaps between the design elements and the fabric, allowing the fabric to breathe and move freely while maintaining adhesion at the design locations. The discrete pieces prevent cracking by allowing independent movement of each segment rather than forcing the entire continuous film to move as one unit.
2Strength
If continuous films or layers are used for heat transfer decoration, then the design is applied reliably without detachment, but the structure lacks flexibility leading to potential cracking
Solution Approach 1:
The design is divided into discrete non-cohesive pieces that are distributed across the fabric surface. Each piece maintains strong adhesion to the fabric, ensuring durability, while the gaps between pieces allow the fabric to flex and stretch without causing the entire design to crack. This segmentation enables the design to accommodate fabric movement while maintaining structural integrity.
3Reliability
If continuous films are applied to athletic materials, then the design adheres well, but the breathability and sweat wicking effectiveness of the material is decreased
Solution Approach 1:
The continuous film is segmented into discrete pieces with gaps between them. These gaps allow moisture vapor and air to pass through the design area, maintaining the breathability and sweat wicking properties of the athletic material. The design elements remain adhered to the fabric through the discrete pieces, ensuring the design stays in place while the fabric performs its moisture management function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances the durability and flexibility of heat transfer decorations, maintaining the breathability of athletic materials by creating non-cohesive designs that can stretch without cracking.
Implementation Method 1
ablating a heat transfer sheet using a defocused laser to define at least one plurality of discrete pieces
Implementation Method 2
the thermo-adhesive layer may be in contact with the fabric, and the desired images or decorations may be applied or fixed to the fabric through the application of heat and pressure
Data Source
AI summary
The present invention provide a multi-layered heat transfer sheet comprising a plurality of distinct pieces forming one or more consecutive patterns that form shapes or objects having discontinuous peripheries, as well as a method for producing and/or making said item. The method for forming the heat transfer decorations includes ablating one or more layers of a heat transfer sheet using a defocused laser to define at least one plurality of discrete pieces that together define a heat transfer decoration. A single pass of the defocused laser may ablate the one or more layers of the heat transfer sheet so as to define the discrete pieces.